Table of contents: Replacing camshaft seals ↓ Removal and installation the… ↓ Removal and installation the… ↓ Checking hydraulic compensators ↓ Replacing valve stem seals ↓
Caution: After installing the camshafts, wait at least 30 minutes before starting the engine to allow the hydraulic lifters to settle. Otherwise, the valves may hit the pistons.
1. Timing belt component installation details are shown on illustrations 12.1 using the example of the left cylinder head.
2. Processing of valves and their seats, except for lapping, is not permitted.
3. When working with the timing belt, arrange the removed parts so that they can then be installed in their original places.
Replacing camshaft seals
4. Remove the upper section of the intake manifold (see Chapter 4).
5. Follow the steps in paragraphs 4-8 Section 12.
Removal and installation the camshafts of the left cylinder head
Note: Special tools are required to install the camshafts.
6. Remove the left upper timing chain from the camshafts (see Section 9).
7. Remove the upper section of the intake manifold (see Chapter 4).
8. Remove the fuel injection pump drive toothed belt (see Chapter 4) and the camshaft gear (see paragraphs 9-10 of Section 11).
9. Remove the left cylinder head cover (see Section 11).
10. Remove the valve from the bracket (1 in the illustration) "N345" EGR cooler.
22.10. Valve "N345" (1), wiring harness (3), bolt (4) and pin (2) for fastening the upper engine cover.
Remove the bolt (4) and mounting pin (2) of the upper engine casing. Move the wiring harness (3) from the upper left coolant pipe to the side.
11. Remove the union nut (1 in illustration 12.13) high-pressure fuel line, unscrew the bolts (arrows) and remove the fuel distribution line from the left cylinder head.
12. Follow the steps in paragraphs 14-24 Section 12.
Removal and installation the camshafts of the right cylinder head
Note: Special tools are required to install the camshafts.
13. Remove the right upper timing chain from the camshafts (see Section 9).
14. Remove the right cylinder head cover (see Section 11).
15. Follow the steps in paragraphs 29-39 Section 12.
Checking hydraulic compensators
Note: Maintenance of hydraulic compensators is not provided. Valve noise immediately after starting the engine does not indicate a malfunction.
16. Start the engine and wait until the coolant temperature rises to approximately 80°C. Increase the engine speed to 2500 rpm for approximately 2 minutes. If necessary, take a test drive.
17. If the hydraulic lifters continue to make noise after this, determine which of them are faulty as described below.
18. Remove the corresponding cylinder head cover (see Section 11). On models before 05.2010, disconnect the air hose (see illustration 17.7)
19. Insert the guide pin with a smaller diameter (2 in illustration 4.73a) into the T40058 adapter. Using this adapter, turn the crankshaft clockwise (see illustration 13.74b) so that the cam for the hydraulic compensator being tested is facing upwards.
20. Press the rocker arm (see illustration 12.44) and determine the gap between the cam and the hydraulic compensator: if it is possible to insert a 0.20 mm thick feeler gauge into this gap, replace the hydraulic compensator (see the subsection "Removing and installing camshafts" above).
21. After checking, install the cylinder head cover and air hose.
Replacing valve stem seals
22. Replacing the valve stem seals is done in the same way as on 1st generation 3.0 TDI engines (see Section 12).
[This publication is borrowed from the resource: AUDIMANUAL.RU]